Mold

ABSTRACT

The improved mold assembly for cultured marble molding is provided. The mold assembly can comprise a male mold portion and a female mold portion. The assembly can further comprise a molding tool. The molding tool can have a side wall having an upper curved portion and a lower curved portion. The molding tool can have a bowl portion and an apron portion spaced from the bowl portion by a gap. The molding tool can be constructed from a flexible and/or soft material. The molding tool can facilitate molding of a countertop having at least one seamless curved edge and/or an at least partially seamless sink portion.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a divisional of U.S. patent application Ser. No.14/444,835, filed Jul. 28, 2014, which claims benefit under 35 U.S.C. §119(e) to U.S. Provisional Patent Application No. 61/875,689, filed Sep.10, 2013, which is incorporated in its entirety by reference herein.U.S. patent application Ser. No. 14/444,835 also claims benefit under 35U.S.C. § 119(e) to U.S. Provisional Patent Application No. 61/876,198,filed Sep. 10, 2013, which is incorporated in its entirety by referenceherein. Any and all priority claims identified in the Application DataSheet, or any correction thereto, are hereby incorporated by referenceunder 37 CFR 1.57.

BACKGROUND Technical Field

This application relates to improved molding tools for moldingcountertops and other structures.

Description of the Related Art

Countertops (e.g., cultured marble countertops) have traditionally beenproduced in fiber glass reinforced plastic (FRP) molds. For example, twoor more mold plates may be mated together in a mating direction to forman internal mold space. Traditionally, FRP molds utilized a positivedraft (e.g., a mold in which every molding surface of every moldcomponent is visible when viewed parallel to the mating direction). Inmany cases, traditional FRP molds are incapable of utilizing negativedrafts (e.g., mold drafts wherein some molding surfaces are hidden fromview when viewed along the mating direction).

SUMMARY

A mold assembly may comprise: a mold frame assembly having a male moldportion and a female mold portion configured to removably mate with themale mold portion, the mold frame defining a mold interior when the malemold portion is mated with the female mold portion; a flexible insertconfigured to fit within the mold interior, the flexible insert having:a bowl portion having a product surface and mold engaging surfaceconfigure to releasably mate with a bowl protrusion on the male moldportion; and an apron integral with the bowl portion, the apron portionhaving a product surface separated from the product surface of the bowlportion by a gap, the apron portion configured to fit within an aproncavity of the female mold portion; the mold frame assembly and theflexible insert define a product mold volume when the male mold portionis mated with the female mold portion and the bowl portion is mated withthe bowl protrusion, the product mold volume defining a product bowlspace at least partially defined by the bowl portion and the apron.

A method of molding a countertop with an integral bowl may comprise:providing a male mold portion having countertop mold projections;providing a flexible insert having a bowl portion having a mold surfaceand a product surface, the flexible insert having an apron portionintegral with the bowl portion and spaced from the bowl portion by a gapdistance, the apron portion having a product surface facing the productsurface of the bowl portion and separated from the product surface ofthe bowl portion by the gap distance; spraying the product surfaces ofthe bowl portion and the apron portion with a gel coat; releasablymating the mold surface of the bowl portion to the male mold; providinga female mold portion having countertop mold recesses; releasably matingthe female mold portion to the male mold portion such that the flexibleinsert is positioned between the female mold portion and the male moldportion, a space between the mated female mold portion and male moldportion defining a mold volume; injecting a composite matrix materialinto the mold volume, wherein the composite matrix material solidifiesafter a setting time to form a countertop having at least one of aseamless front side and a seamless side end; unmating the female moldportion from the male mold portion after the setting time has takenplace; and removing the flexible insert from the countertop.

A mold assembly may comprise: a mold frame assembly having a male moldportion and a female mold portion configured to removably mate with themale mold portion at least partially on a mating plane, the mold framedefining a mold interior when the male mold portion is mated with thefemale mold portion; and a flexible insert configured to fit within themold interior, the flexible insert having: a main body portion having anouter perimeter; and at least one sidewall extending from the outerperimeter of the main body portion, the sidewall having an upper curvedportion and a lower curved portion, both the upper curved portion andthe lower curved portion curved toward the main body portion from avertical plane perpendicular to the mating plane and tangential to theouter perimeter of the main body portion of the flexible insert; whereinthe mold frame assembly and the flexible insert define a product moldvolume when the male mold portion is mated with the female mold portionand the bowl portion is mated with the bowl protrusion, the product moldvolume having at least one side portion having an upper curved portionand a lower curved portion, the side portion being seamless along andbetween the upper curved portion and the lower curved portion of theside portion.

A method of molding a countertop may comprise: providing a male moldportion having countertop mold projections; providing a female moldportion having countertop mold recesses, the female mold portionconfigured to releasably mate with the male mold portion at leastpartially on a mating plane; providing a flexible insert having a mainbody portion having an outer perimeter and at least one sidewallextending from the outer perimeter of the main body portion, thesidewall having an upper curved portion and a lower curved portion, boththe upper curved portion and the lower curved portion curved toward themain body portion from a vertical plane perpendicular to the matingplane and tangential to the outer perimeter of the main body portion ofthe flexible insert; spraying one or more surfaces of the flexibleinsert with a gel coat; releasably mating the flexible insert with oneof the male mold portion and the female mold portion; releasably matingthe female mold portion to the male mold portion such that the flexibleinsert is positioned between the female mold portion and the male moldportion, a space between the mated female mold portion and male moldportion defining a mold volume; injecting a composite matrix materialinto the mold volume, wherein the composite matrix material solidifiesafter a setting time to form a countertop having at least one sideportion having an upper curved portion and a lower curved portion, boththe upper curved portion and the lower curved portion of the sideportion curved toward a counter portion of the countertop from avertical plane perpendicular to the mating plane and tangential to anouter perimeter of the counter portion of the countertop, the sideportion being seamless along and between the upper curved portion andthe lower curved portion of the side portion; unmating the female moldportion from the male mold portion after the setting time has takenplace; and removing the flexible insert from the countertop.

BRIEF DESCRIPTION OF THE DRAWINGS

These and other features and advantages of the present embodiments willbecome more apparent upon reading the following detailed description andwith reference to the accompanying drawings of the embodiments, inwhich:

FIG. 1 is a perspective exploded view of an embodiment of a moldassembly.

FIG. 1A is a rear exploded view of the mold assembly of FIG. 1.

FIG. 2A is a bottom perspective view of an embodiment of a molding tool.

FIG. 2B is a top perspective view of the molding tool of FIG. 2A.

FIG. 2C is a top elevation view of the molding tool of FIG. 2A.

FIG. 2D is a side cross-section view of the molding tool of FIG. 2A.

FIG. 3A is a top perspective view of an embodiment of a molded product.

FIG. 3B is a bottom perspective view of the molded product of FIG. 2A.

FIG. 3C is a top elevation view of the molded product of FIG. 2A.

FIG. 3D is a side cross-section view of the molded product of FIG. 2A.

FIG. 4 is a top perspective exploded view of another embodiment of amold assembly.

FIG. 4A is a rear exploded view of the mold assembly of FIG. 4.

FIG. 4B is a bottom perspective exploded view of the mold assembly ofFIG. 4.

FIG. 5 is a top elevation view of the molded product of FIG. 4.

DETAILED DESCRIPTION

An improved mold assembly is disclosed herein. The embodiments disclosedherein are described in the context of a mold assembly for use inmodeling sinks and countertops because the embodiments disclosed hereinhave particular utility in this context. However, the embodiments andinventions herein can also be applied to molding other types of solidsurface products, including but not limited to tabletops, cuttingboards, floor tiles, sculptures or other products.

A mold assembly 100 can include a male mold portion (e.g., male moldplate 102) and a female mold portion (e.g., female mold plate 104). Themale mold plate 102 and female mold plate 104 can be configured toreleasably mate with each other. The male mold plate 102 and female moldplate 104 can each form, separately or in combination, a mother tool. Insome embodiments, more than two (e.g., 3, 4, 6, 10, 15, etc.) moldplates may be combined to form a mother tool. When mated, the moldplates 102, 104 may define a mold interior (e.g., the volume of spacebetween the mold plates 102, 104 when the mold plates 102, 104 aremated). As illustrated in FIG. 1, the mold plates 102, 104 can matealong a mating plane (e.g., the plane defined by the top surface 109 ofthe female mold plate 104). In some embodiments, the mold plates 102,104 are oriented as shown in FIG. 1 during the molding process (e.g.,female mold plate 104 beneath male mold plate 102). In some embodiments,the female mold plate 104 is positioned above the male mold plate 102during the molding process. In some cases, the mold plates 102, 104 arepositioned beside each other or at some other relative orientationduring the molding process.

The female mold plate 104 can include one or more cavities/recesses 108for receiving a molding or soft tool (e.g., a flexible insert 200)and/or for defining a shape of a molded product 300. As illustrated inFIG. 1A, the male mold plate 102 can include one or more protrusions 103for receipt by the flexible insert 200 and/or for defining a shape ofthe molded product 300.

As illustrated in FIG. 2A, the flexible insert 200 can include a mainbody portion 204. Portions of or the entire flexible insert 200 can beconstructed from a soft and/or flexible material (e.g., rubber,polymers, latex, or other soft and/or flexible materials). The flexibleinsert 200 can include a bowl portion 208 projecting from the main bodyportion 204. Preferably, the bowl portion 208 and the main body portion204 form a monolithic part. The bowl portion 208 can have a productsurface (e.g., the convex surface of the bowl portion 208) and a moldengagement surface (e.g., the concave surface of the bowl portion 208).In some embodiments, the product surface of the bowl portion 208comprises the first opposing surface 203 of the bowl portion 208opposing a second opposing surface 205 of an apron 212, as illustratedin FIG. 2D and described below. The mold engagement surface can beconfigured to releasably mate with the male mold plate 200 (e.g., withone or more protrusions 103 on the male mold portion).

The main body portion 204 may have an outer perimeter from whichsidewalls 216 and front walls 220 project. A portion of the outerperimeter of the main body portion 204 may include a back wall 224. Thewalls 216, 220 are preferably integral with the main body portion 204 toform a monolithic part. The front walls 220 and/or sidewalls 216 caninclude an upper curved portion 219 and a lower curved portion 217(upper and lower corresponding to the orientation of the insert when theinsert is positioned with the drain opening 207 facing upward, as inFIG. 2A). For example, the sidewalls 216 can include an upper curvedportion 219 that curves inward (e.g., toward the body portion 204) froma vertical plane. The vertical plane can be plane tangential to a pointon the outer perimeter of the main body portion 204. The vertical planemay be parallel to a vertical line VL1 (e.g., see FIG. 2A) and/orperpendicular to a plane on which the main body portion 204 lies. Insome embodiments, the vertical plane is perpendicular to the matingplane of the male mold plate 102 and the female mold plate 104. In someembodiments, the vertical plane is parallel to a separation line 105 ofthe two mold portions (e.g., the direction in which one or both of themold plates 102, 104 is moved to mate and unmate from the other moldplate 102, 104). The sidewalls 216 may include a lower curved portion217 that curves inward (e.g., toward the body portion 204) from avertical plane (e.g., the vertical plane as described above). In someembodiments, the back wall 224 lies at least partially on a verticalplane on a back side of the tool 200. The sidewalls 216 can be seamless(e.g., lacking in any seam produced by the interface of two or morecomponents of the mold assembly 100—such as between the male mold plate102 and the female mold plate 104) between the upper curved portions 219and the lower curved portions 217. In some embodiments, the sidewalls216 and/or front wall 220 have negative drafts. In some embodiments, thesidewalls 216 and/or the front wall 220 have structural detailing (e.g.,protrusions, indentations, artistic patterns, ribs, etc.). Thestructural detailing of the sidewalls 216 and/or of the front wall 220can be located on and/or between the upper curved portions 219 and thelower curved portions 217. The upper curved portion 219 and/or the lowercurved portion 217 may have a radius of curvature of greater than orequal to ⅛ inches. In some embodiments the radius of curvature of thecurved portions 217, 219 is greater than or equal to 0.25 inches. Insome embodiments curved portion can define a radius. In someembodiments, the radius of curvature of the curved portions 217, 219 isgreater than or equal to 1 inch. Many variations are possible,including, but not limited to, radii of curvature that vary along thelengths of the curved portions 217, 219. In some embodiments, the frontwalls 220 have upper and lower curved portions that are the same orsimilar in curvature and layout to the upper and lower curved portions217, 219 of the sidewalls 216.

The flexible insert 200 can include an apron 212. The apron 212 can havea product surface (e.g., the concave surface of the apron 212) and amold engaging surface (e.g., the convex surface of the apron 212). Insome embodiments, the product surface of the apron 212 comprises thesecond opposing surface 205 of the apron 212 opposing the first opposingsurface 203 of the bowl portion 208. Preferably, the apron 212 isintegral with the main body portion 204 of the tool 200 (e.g., the apron212, bowl portion 208, and main body portion 204 form a monolithicpart). In some embodiments, the apron 212 connects to the main bodyportion 204 along a portion of the front wall 220. The product surfaceof the apron 212 can be spaced from the product surface of the bowlportion 208 by a gap G (e.g., see FIG. 2D). In some embodiments, the gapG is defined as the shortest distance between the spaced opposingsurfaces 203, 205 (e.g., the spaced opposing product surfaces of thebowl portion 208 and the apron 212). In some embodiments, the gap G isgreater than or equal to about 0.1 inches and/or less than or equal toabout 12 inches. In some embodiments, the gap G is approximately ⅜inches. In some embodiments, the gap G is approximately ½ inch, 1 inch,2 inches, 3 inches, 4 inches, 5 inches, 6 inches, 7 inches, 8 inches, 9inches, 10 inches, or any value therebetween. In some embodiments, thegap G is less than ¼ inches, less than ⅜ inches, less than ½ inches,less than ¾ inches, less than ⅞ inches, less than 1 inch, less than 2inches, less than 3 inches, less than 4 inches, less than 5 inches, lessthan 6 inches, less than 7 inches, less than 8 inches, less than 9inches or less than 10 inches. In some embodiments, the gap G is between¼ inches and 8 inches, between ⅜ inches and 6 inches, or between 1 inchand 5 inches. Many variations are possible. The apron 212 can beconfigured to fit at least partially within an apron cavity of thefemale mold plate 104.

The space between the flexible insert 200 and the mold plates 102, 104can define a product mold volume when the mold plates 102, 104 are matedtogether and the flexible insert 200 is mated with one or more of themold plates 102, 104 within the mold interior. A gel coating may beapplied (e.g., sprayed, painted) on the product surface of the bowlportion 208 and the apron 212. In some embodiments, the product surfacesof the bowl portion 208 and apron 212 may be sprayed and/or painted witha gel coating (e.g., a polyester gel coat) prior to and/or after matingthe flexible insert with one of the mold plates 102, 104. For example,the apron 212 may be flexed away from the bowl portion 208 to permitaccess by the gel coat sprayer or other gel coat applied to the productsurfaces of the bowl portion 208 and the apron 212. The flexible and/orsoft material of the flexible insert 200 can be flexible enough todeflect to permit a sprayer (e.g., a gel coat sprayer as discussedbelow) to be positioned within 1 inch, within 2 inches, within threeinches, within 4 inches, within 5 inches, or within 6 inches of theproduct surfaces of the bowl portion 208 and the apron 212. Some or allof the interior surfaces (e.g., the recesses of the female mold plate104 and/or the protrusions of the male mold plate 102) may be sprayedwith a gel coating prior to mating of the mold plates 102, 104. The gelcoat may be sprayed on the interior surface of the mold plates 102, 104and/or on the product surfaces of the bowl portion 208 and apron 212 ina precisely controlled layer (e.g., a substantially consistentthickness). The gel coat may be transparent, translucent, and/or opaque.In some embodiments, the gel coat has a color (e.g., white, black, gray,red, green, etc.). The gel coat may have multiple colors or textures.The product mold volume may include a product bowl portion at leastpartially defined by the distance (e.g., the gap G) between the apron212 and the bowl portion 208 of the flexible insert 200.

Cultured marble, a composite matrix material, or some other solidsurface material may be injected or poured into the product mold volume.For example, solid surface material may be poured through an opening inone of the male mold plate 102 and the female mold plate 104. In somecases, a composite matrix material is used to back the gel coat afterthe gel coat is applied to the interior surface of the mold plates 102,104 and/or on the product surfaces of the bowl portion 208 and apron212. For example, the composite matrix material can be poured into theproduct mold volume to cover the surfaces of the mold assembly 100 onwhich gel coat has been previously applied. In some embodiments, thesolid surface material is poured through an opening at or near a sinkdrain portion of the female mold plate 104. The solid surface materialmay be left in the product mold volume until the solid surface materialsets (e.g., solidifies and/or hardens). For example, the solid surfacematerial may be left in the product mold volume until a composite set orthermoset process is completed. The use of a molding tool (e.g., theflexible insert 200) can allow for negative draft molding. In someembodiments, the flexible insert 200 is removed from the mold plates102, 104 (e.g., the mother tool) when the setting process is complete.The flexible insert 200 may be removed from the solid surface materialupon completion of the setting and/or molding process.

In some embodiments, setting of the solid surface material in theproduct mold volume results in the formation of a coated product (e.g.,the countertop 300 of the FIGS. 1 and 3A-3D). The countertop 300 maycomprise solidified solid surface material with a gel coat finish. Asillustrated in FIGS. 3A-3D, the countertop 300 can include a counterportion 304. The counter portion 304 may have an outer periphery definedby side ends 316, a front end 318, and a back end 324. The countertop300 may include a sink portion 308. The sink portion 308 and countertop300 may form a monolithic part. The sink portion 308 can have an outerrim 312. The outer rim 312 may be seamless. The sink portion 308 may beat least partially formed within the product bowl portion of the productmold volume. The sink portion 308 can be integral with the counterportion 304. The sink portion 308 may be seamless. In some embodiments,the front end 318 of the counter portion 304 includes two outer frontportions 320 and the outer rim 312.

The side ends 316 and/or front end 318 of the counter portion 304 may beseamless. In some embodiments, the front end 318 and/or side ends 316can include an upper curved portion 319 and a lower curved portion 317.For example, side ends 316 can include an upper curved portion 319 thatcurves inward (e.g., toward the counter portion 304) from a verticalplane. In some embodiments, as illustrated in FIG. 4A, the side ends 316include an upper curved portion or a lower curved portion, but not both.The vertical plane can be plane tangential to a point on the outerperimeter of the counter portion 304. The vertical plane may be parallelto a vertical line VL2 (e.g., see FIG. 3B) and perpendicular to a planeon which the counter portion 304 lies. In some embodiments, the verticalplane is perpendicular to the mating plane of the male mold plate 102and the female mold plate 104. The side ends 316 may include a lowercurved portion 317 that curves inward (e.g., toward the counter portion304) from a vertical plane as described above. For example, the verticalplane can be parallel to the separation line 105 described above. Insome embodiments, the back end 324 lies at least partially on a verticalplane on a back side of the countertop 300. The side ends 316 can beseamless. The upper curved portion 319 and/or the lower curved portion317 of the side ends 316 and/or front end 318 may have a radius ofcurvature to match the radii of curvature of the upper and lower curvedportions 219, 217 of the flexible insert 200.

As illustrated in FIGS. 3A-3D, the sink portion 308 of the countertop300 may have a rim 312. The rim 312 may have a thickness T (e.g., athickness measured substantially parallel to the counter portion 304 andsubstantially perpendicular to a point on the concave surface of the rim312). As illustrated in FIG. 3D, the sink portion 308 may have anapron-formed portion 314 have a thickness similar to or the same as thethickness T of the rim 312. The thickness T may be similar to orsubstantially the same as the gap G of the flexible tool 200 used toform the countertop 300. In some embodiments, the thickness T may besubstantially the same as a thickness of the sink portion 308 outsidethe apron-formed portion 314 (e.g., the sink portion 308 may have asubstantially uniform thickness). As illustrated, the width W of thecounter portion 304 can be similar to or substantially the same as thedistance between the sidewalls 216 of the flexible tool 200 and the bowlportion 208 of the flexible tool 200.

FIGS. 4-5 illustrate an embodiment of a mold assembly 100′ that can havecomponents or portions that are the same as or similar to the componentsor portions of the mold assembly 100. Numerical reference to componentsis the same as previously described, except that a prime symbol (′) hasbeen added to the reference. Where such references occur, it is to beunderstood that the components are the same or substantially similar topreviously-described components. As illustrated, the male mold plate102′ can include a main plate body 102 a and a backing plate portion 102b. In some embodiments, an elastomeric seal is positioned between themain plate body 102 a and the backing plate portion 102 b. The femalemold plate 104′ can include a front plate portion 104 a. The front plateportion 104 a can be removably attached to a main female plate portion104 b. In some cases, the female mold plate 104′ includes a removableback plate 104 c. One or more elastomeric seals can be positionedbetween the front plate portion 104 a, the main female plate portion 104b, and the back plate 104 c. As illustrated in FIG. 5, the width W′ ofthe counter portion 304′ of the molded product 300′ can be less than thewidth W of the counter portion 304 of the molded product 300 illustratedin FIG. 3C.

The terms “approximately,” “about,” “generally” and “substantially” asused herein represent an amount close to the stated amount that stillperforms a desired function or achieves a desired result. For example,the terms “approximately,” “about,” “generally,” and “substantially” mayrefer to an amount that is within less than 10% of the stated amount.

Although the mold assembly has been disclosed in the context of certainpreferred embodiments and examples, it will be understood by thoseskilled in the art that the present disclosure extends beyond thespecifically disclosed embodiments to other alternative embodimentsand/or uses of the mold assembly and obvious modifications andequivalents thereof. In addition, while a number of variations of themold assembly have been shown and described in detail, othermodifications, which are within the scope of this disclosure, will bereadily apparent to those of skill in the art based upon thisdisclosure. It is also contemplated that various combinations orsub-combinations of the specific features and aspects of the embodimentsmay be made and still fall within the scope of the disclosure.Accordingly, it should be understood that various features and aspectsof the disclosed embodiments can be combined with or substituted for oneanother in order to form varying modes of the disclosed mold assemblies.Thus, it is intended that the scope of the present disclosure hereindisclosed should not be limited by the particular disclosed embodimentsdescribed above, but should be determined only by a fair reading of theclaims that follow.

What is claimed is:
 1. A mold assembly for cultured marble moldingcomprising: a mold frame assembly having a male mold portion and afemale mold portion configured to removably mate with the male moldportion, the mold frame assembly defining a mold interior when the malemold portion is mated with the female mold portion; and a flexibleinsert configured to fit within the mold interior, the flexible inserthaving: a bowl portion having a product surface and a mold engagingsurface configured to releasably mate with a bowl protrusion on the malemold portion; and an apron portion integral with the bowl portion, theapron portion having a product surface separated from the productsurface of the bowl portion by a gap, the apron portion configured tofit within an apron cavity of the female mold portion, wherein theproduct surface of the apron portion is concave and curved in a firstdirection and in a second direction perpendicular to the firstdirection; wherein the mold frame assembly and the flexible insertdefine a product mold volume when the male mold portion is mated withthe female mold portion and the bowl portion is mated with the bowlprotrusion, the product mold volume defining a product bowl space atleast partially defined by the bowl portion and the apron portion. 2.The mold assembly of claim 1, wherein the mold frame assembly and theflexible insert cooperate to define at least one of a seamless curvedside portion and a seamless curved front portion interfacing with theproduct mold volume, wherein the at least one of the seamless curvedside portion and the seamless curved front portion is curved toward thebowl portion.
 3. The mold assembly of claim 2, wherein the seamlesscurved side portion and seamless curved front portion each comprise anupper curved portion and a lower curved portion.
 4. The mold assembly ofclaim 1, wherein the gap between the product surface of the apronportion and the product surface of the bowl portion can be increased bydeflecting at least a portion of the apron portion away from the bowlportion.
 5. The mold assembly of claim 1, wherein the male mold portioncomprises a plurality of separable male mold sections.
 6. The moldassembly of claim 1, wherein the female mold portion comprises aplurality of separable female mold sections.
 7. The mold assembly ofclaim 1, wherein the flexible insert is constructed from a resilientmaterial.
 8. A mold assembly for cultured marble molding comprising: amold frame assembly having a male mold portion and a female mold portionconfigured to removably mate with a bowl protrusion on the male moldportion at least partially on a mating plane, the mold frame assemblydefining a mold interior when the male mold portion is mated with thefemale mold portion; and a flexible insert configured to fit within themold interior, the flexible insert having: a main body portion defininga bowl portion and having an outer perimeter; at least one sidewallextending from the outer perimeter of the main body portion, the atleast one sidewall having an upper curved portion and a lower curvedportion, both the upper curved portion and the lower curved portioncurved toward the main body portion from a vertical plane perpendicularto the mating plane; and an apron portion separated from the bowlportion by a gap, wherein the apron portion is concave and curved in afirst direction and in a second direction perpendicular to the firstdirection; wherein the mold frame assembly and the flexible insertdefine a product mold volume when the male mold portion is mated withthe female mold portion and the bowl portion is mated with the bowlprotrusion, the product mold volume having at least one side portionhaving an upper curved portion and a lower curved portion, the at leastone side portion of the product mold volume being seamless along andbetween the upper curved portion and the lower curved portion of the atleast one side portion.
 9. The mold assembly of claim 8, wherein aradius of curvature of the lower curved portion of the at least onesidewall changes along the outer perimeter of the main body portion. 10.The mold assembly of claim 8, wherein a radius of curvature of the uppercurved portion of the at least one sidewall changes along the outerperimeter of the main body portion.
 11. The mold assembly of claim 8,wherein the gap between the apron portion and the bowl portion can beincreased by deflecting at least a portion of the apron portion awayfrom the bowl portion.
 12. The mold assembly of claim 8, wherein theflexible insert is constructed from a resilient material.
 13. A moldassembly for cultured marble molding comprising: a mold frame assemblyhaving a male mold portion and a female mold portion configured toremovably mate with the male mold portion, the mold frame assemblydefining a mold interior when the male mold portion is mated with thefemale mold portion; and a flexible insert configured to fit within themold interior, the flexible insert having: a bowl portion configured toreleasably mate with a bowl protrusion on the male mold portion; and anapron portion separated from the bowl portion by a gap, wherein theapron portion is curved in a first direction and in a second directionperpendicular to the first direction; wherein the mold frame assemblyand the flexible insert define a product mold volume when the male moldportion is mated with the female mold portion and the bowl portion ismated with the bowl protrusion, the product mold volume defining aproduct bowl space at least partially defined by the bowl portion andthe apron portion.
 14. The mold assembly of claim 13, wherein the gapbetween the apron portion and the bowl portion can be increased bydeflecting at least a portion of the apron portion away from the bowlportion.
 15. The mold assembly of claim 13, wherein the flexible insertis constructed from a resilient material.
 16. The mold assembly of claim13, wherein the bowl portion comprises a mold surface and a productsurface, the product surface of the bowl portion being convex and curvedin the first direction and in the second direction, and wherein theapron portion comprises a product surface that is concave and curved inboth the first and second directions.